HORNBACH CFH ISG 147 Inverter Welder Instruction Manual

HORNBACH CFH ISG 147 Inverter Welder

IMBPORTANT
CAREFULLY READ THE FOLLOWING IN-STRUCTIONS BEFORE INSTALLING THE UNIT AND MAKE SURE THAT THE YEL-LOW AND GREEN GROUNDING CON-DUCTOR IS DIRECTLY CONNECTED TO THE GROUND IN THE WELDING LOCA-TION.
THE UNIT MUST NEVER BE OPERATED WITHOUT PANELS AS THIS COULD BE DANGEROUS FOR THE OPERATOR AND COULD CAUSE SERIOUS DAMAGE TO THE EQUIPMENT.
THE UNIT WORKS ONLY WITH INPUT VOLTAGE OF 230Vac -50 Hz-1Ph.
THE INPUT CABLE IS ENERGIZED EVEN WHEN THE MAIN SWITCH IS ON THE “0” POSITION. THEREFORE, BEFORE SER-VICING THE EQUIPMENT, MAKE SURE THAT THE 2 POLE PLUG IS DISCON-NECTED FROM THE LINE SOCKET.

INTRODUCTION

EQUIPMENT IDENTIFICATION

The unit’s identification number (specification or part number) model, and serial number usually appear on a nameplate attached to the rear panel. Equipment which does not have a control panel such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container. Record these numbers for future reference.

RECEIPT OF EQUIPMENT

When you receive the equipment, compare it with the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. All machines dispatched have been scrupulously checked. However, should your machine not work properly, consult the section on TROUBLE SHOOTING in this manual. If the fault persists, consult your authorized dealer.

SAFETY WARNING

GENERAL INSTRUCTIONS

This manual contains all the necessary instructions for:

• The installation of the equipment;
• a correct operating procedure;
• an adequate maintenance of the equipment. Therefore, be sure this manual is carefully read and understood by the maintenance and technical operators.

LOCATION

Welding processes of any kind can be dangerous not only to the operator but to any person situated near the equipment if safety and opera-ting rules are not strictly observed.
Therefore the owner and the operator must be aware of all possible risks so that they may take the necessary safety precautions to avoid any kind of accident at work.

The main precautions to be observed are:

• Operators should protect their body by wearing non flammable, close fitting protective clothing, without pockets or turned-up trousers. Oil or grease should be carefully removed from all articles, before wearing. Operators should also wear closed safety boots with steel toe caps and with rubber soles ( Fig. 1).

1. Leather gloves
2. Leather aprons
3. Shoes Cover
4. Security shoes
5. Face mask
6. Crust leather sleeves to protect the arms.

According to the requirements in 2006/25/EC Directive and EN 12198 Standard, the equipment (EN 12198)Category 2 is a category 2. It makes compulsory the adoption of Personal Protective Equipment (PPE) having filter with a protection degree up to a maximum of 15, as required by EN169 Standard.

• Operators should wear a non- flammable welding helmet or face shield designed so as to shield the neck and the face, also on the sides. The helmet or the face shield should be fitted with protective glasses adequate to the welding process and current used. Glass screens must always be kept clean, and immediately replaced if they are broken or cracked (Fig.2). It is good practice to install a pane of transparent glass on top of the Adi actinic glass, between it and the welding area. This pane can be frequently replaced when incandescent spatters and deposits greatly reduce visibility. When working with coated plates that emit toxic fumes when heated, use an air-supplied respirator.

• Welding should be done in a closed area that does not open onto other working areas, in order to protect all workers against radiation and fumes. If such an area cannot be provided, the welding area must be delimi-ted by protective screens painted in opaque black large enough to restrain the visibility of any person situated near the area (Fig. 3).

• Remove all chlorinated solvents from the welding area before welding. Certain chlorinated solvents decompose when exposed to ultraviolet radiation to form phosgene gas.

• Never, under any circumstances, look at an electric arc without suitable eye protection (Fig. 4).
  Fig.4

• Always wear protective goggles with transparent lenses to prevent splinters or other foreign particles from harming the eyes (Fig. 5). Fig.5

• Adequate local exhaust ventilation must be used in the area. It should be provided through a mobile hood or through a built-in system on the workbench that provides exhaust ventilation from the sides, the front and below, but not from above the bench so as to avoid raising dust and fumes. Local exhaust ventilation must be provided together with adequate general ventilation and air circulation, particularly when work is done in a confined space.
  (Fig.6). Any symptom of stain or soreness to the eyes, the nose or the throat may be cause by inadequate ventilation; work must be stopped immediately and all necessary steps must be taken to provide adequate ventilation.

• Welding process must be performed on metal coatings thoroughly cleaned from layers of rust or paint, to avoid production of harmful fumes. The parts degreased with a solvent must be dried before welding.

• Do not weld metal or painted metal containing zinc, lead, cadmium or beryllium unless the operator, or anyone else subjected to the fumes, is wearing respiratory equipment or an air-supplied helmet.

• The employer is required to evaluate the risks to which workers are exposed during the use of welding machines, focusing in particular on the risks deriving from the welding of stainless steel alloys. In relation to the legislation in force in the country where the welding machines are sold, the employer who uses the welding machines to weld stainless steel alloys is required to evaluate the carcinogenic risk deriving from the development of welding fumes containing nickel and hexavalent chromium in gaseous form (remember that nickel and hexavalent chromium in the gaseous state are carcinogenic).

SAFETY INSTRUCTIONS

For your safety, before connecting the source to the line, closely follow these instructions: – an adequate two-pole switch must be inserted before the two-pole main outlet; this switch must be equipped with time-delay fuses and it must match the data specified in the chapter “Technical Specification”;

• the mono-phase connection with ground must be made with a two-pole plug compatible with the above mentioned socket;
• two wires of the two-pole input cable are used for the connection with the mono-phase line and the yellow-green wire for the compulsory connection to the ground in the welding location;
• connect all the metal parts which are near the operator in the welding location by using cables bigger or of the same cross section of the welding cable to a ground terminal;
• when working in a confined space, the power source must be kept outside the welding area and the ground cable should be welded to the workpiece; do not work in a damp or wet area in these conditions (Fig. 7).
• do not use damaged welding or input cables (Fig. 8);
• the operator should never touch, with any part of his body, high temperature or electrically hot metal parts (Fig. 9);
• the operator should never wind the welding cables around his body;
• the welding gun should never be pointed at the operator or at another person. The power source has a protection level IP 22; therefore, it prevents:
• any manual contact with hot or moving internal parts;
• the insertion of any solid body with more than 12mm diameter;
• protected against vertically falling drops of water (condensation) with inclination max of 15°.
  The source must never be operated without its panels; this could cause serious injury to the operator and could damage the equipment itself.

FIRE PREVENTION

The working area should conform to the Safety Regulations, and therefore, fire extinguishers should be provided in the area and walls, ceiling and floor should be non-flammable. All combustible material must be moved from the welding area (Fig. 10). If combustibles cannot be moved, they must be protected with fire-resistant cover. Ventilate potentially flammable atmospheres before welding. Never operate in an atmosphere which contains heavy concentrations of dust, flammable gas or combustible liquid vapor.
The power source must be located in a safe area with a firm and flat floor; it should not be put against a wall. Do not weld containers in which fuel, lubricant or any other flammable material have been stored. After having completed your work, always check that the area is free of glowing or smoldering material.

SHIELDING GAS

Use the correct shielding gas for the welding process. Be sure that the regulator/flowmeter mounted on the cylinder is working well. Remember to keep away the cylinder from any source of heat.

PERMITTED NOISE LEVELS 86/188 EEC RULE.

Under normal circumstances the equipment used for electric arc welding does not exceed the permitted 80 dBA. However in certain conditions eg. high welding parameters in confined spaces, noise levels may exceed the permitted level. For this reason it is strongly recommended that operatives wear appropriate ear protection.

ELECTROMAGNETIC COMPATIBILITY

Before installing the STICK/TIG welding unit, carry out an inspection of the surrounding area, observing the following guidelines:

1. Make sure that there are no other power supply cables, control lines, telephone leads or other equipment near the unit.
2. Make sure that there are no radio receivers or television appliances.
3. Make sure there are no computers or other control systems.
4. Make sure that there is no-one with a pacemaker or hearing aid in the area around the unit.5- Check the immunity of any other equipment operating in the same environment.
   In certain cases additional protective measures may be required.

Interference can be reduced in the following ways:

1. If there is interference in the power supply line, an E.M.C. filter should be inserted between the mains and the unit.
2. The output cables of the unit should be shortened; these should be kept close together and stretched along the ground.
3. All the panels of the unit should be correctly closed after carrying out maintenance.

MEDICAL AND FIRST AID TREATMENT

First aid facilities and a qualified first aid person should be available for each shift for im-mediate treatment of electrical shock victims. A medical facility should be close by for immediate treatment of flash burns of the eye and skin burns.

EMERGENCY FIRST AID:
Call physician and ambulance immediately.
Use First Aid techniques recommended by The Red Cross.

DANGER: ELECTRIC SHOCK CAN BE FATAL
If person is unconscious and electric shock is suspected , do not touch the person if he or she is in contact with wel-ding equipment, or other live electrical parts. Disconnect (open) power at wall switch and then use First Aid. Dry wood, wooden broom, or other insulating material can be used to move cables, if necessary, away from the person.

INSTALLATION OF THE EQUIPMENT

Proper operation of the generator is ensured by adequate installation. The assembly of the inverter must be done by expert people, following the instructions and in full respect of the safety standards.

• Remove the welder from the carton box.
  BEFORE ATTEMPTING ANY ELECTRI-CAL CONNECTION CHECK THE DATA PLATE AND MAKE SURE THAT THE IN-PUT VOLTAGE AND THE FREQUENCY ARE THE SAME OF THE MAINS OUTLET TO BE USED.

EARTHING

• To protect users the welding machines must be connected properly to the earth (ground) system (INTERNATIONAL SAFETY REGULATIONS).

• It is indispensable to earth (ground) the machine properly with the yellow-green conductor of the power supply cable, in order to avoid discharges due to accidental contacts with earthed objects.

• The chassis (that is conductive) is electrically connected to the earth conductor. Failure to earth the equipment correctly can cause electric shocks dangerous to the users.

• Plug the inverter to the mains.
  Do not use the generator with input cables’ extensions longer than 10m and thinner than 2.5mm². Remember to keep them layer and not wound or entangled.
  Do not use the welder with the side panels partially or completely removed in order to avoid accidental contacts with inner live parts.

• The inverter is now ready for use. Make sure you are welding in a properly ventilated area and that the ventilation openings of the machine are not obstructed (poor air ventilation may reduce the duty cycle of the unit and cause damages). Now you may choose the welding process by connecting the accessories as showed in the following pages.

INVERTER FUNCTIONS AND CONNECTIONS

1. Adjusting welding current potentiometer

2. Green Led indicating power ON
   Led ON = Power ON
   Led OFF = Power OFF

3. Yellow Led
   Led ON = indicating temperature limits are exceeded.
   Warning: Let unit to cool down. When ready, the orange led will automatically shut off.
   Led ON = indicating short circuit.

4. 25mm² positive socket

5. 25mm² negative socket

6. Input Cable

7. ON/OFF Switch

STICK WELDING

General information
The electric arc may be described as a source of bright light and strong heat; in fact, the flow of electric current in the gas atmosphere which surrounds the electrode and the workpiece determines the radiation of electromagnetic waves that can be perceived as light and/or heat depending on their wave length. At an unperceivable level, the arc also produces ultra-violet and infra-red light; ionizing rays have never been noted. The heat produced by the arc is used in the welding process to melt and join metal parts. The necessary electric current is supplied by special equipment commonly called welding machine.

• Connect the earth cable to the negative pole of the Inverter and the earth clamp to the workpiece.

• Connect the welding cable to the positive pole of the Inverter.

• Select the welding current using the potentiometer on the front panel. The welding cur-rent should be chosen following the instruction given by the electrodes manufacturer on the electrode box, but the following indications may be useful as general information:
  ELECTRODEDIAMETER| WELDINGCURRENT
  ---|---
  1.5mm| 30 A – 40A
  2.0mm| 50 A – 65 A
  2.5mm| 70 A – 100 A
  3.25mm| 100 A – 140 A
  4.0mm| 140 A – 160 A

• Switch the Inverter on. The two leds on the front panel will be respectively the green = lit and the yellow = off (for more details refer to section before).

• Protect your face with a mask or a helmet. Touch, with the electrode fastened, in the electrode holder, the work piece until the arc will be struck.
  Avoid hammering the workpiece with the electrode since it may loose the coating and increase the arc striking difficulties.

• After striking the arc keep feeding the electrode into the weld pool with an angle of about 60° and moving left to right so that you may control visually the welding. The length of the arc can also be controlled by lifting or lowering slightly the electrode. Also a variation of the welding angle may increase the size of the weld pool improving the capacity of surfacing of the slag.

• At the end of the weld let the slag cool off before removing it, using the brush-hammer.

CAUTION: Protect your eyes when hitting the slag with the chip hammer to avoid damages.
CAUTION: A bad start can be due to the dirty workpiece, a bad connection between earth cable and work piece, or the bad fastening of the electrode in the electrode holder.

QUALITY OF THE WELD

The quality of the weld will depend mainly on the ability of the welder, on the type of weld and on the quality of the electrode: Choose the proper electrode before attempting to weld, paying attention to the thickness and composition of the metal to be welded.

Correct welding current.
If the current is too high the electrode will burn fast and the weld pool will be wide irregular and difficult to be controlled. If the current is too low you will lack power and the weld pool will be narrow and irregular.

Correct arc length.
If the arc is too long it will cause spatters and small fusion of the welding piece. If the arc is too short the arc heat will be insufficient causing the electrode to stick to the workpiece.

Correct welding speed.
The correct welding speed will consent to achieve a weld of proper width, without waves or craters.

ORDINARY MAINTENANCE CAUTION!!!

BEFORE CARRY OUT ANY MAINTENAN-CE, UNPLUG THE MACHINE FROM THE MAINS POWER SUPPLY.

The efficiency of the welding system over time is directly related to the frequency of maintenance jobs, such as:
For welding machines only need to be ta-ken care inside. The dustier the working environment is, the more often this should be done.

• Take off the lid.
• Remove all traces of dust in the inner parts of the generator with a jet of compressed air at a pressure under 3Kg/cm.
• Check all electrical connections, making sure that nuts and screws have been firmly tightened.
• Do not delay in replacing worn-out parts.
• Put the lid back on.
• After completing the above operations, the generator is ready to be restarted following the instructions given in this manual.

POSSIBLE WELDING DEFECTS

Electrode oscillates too much.

Workpieces are too far apart. Workpiece being welded is cold.

| Use basic electrodes.

Move edges to be welded closer together.

Move slowly at the beginning.

Lower welding current.

CRACKS| Material to be welded is dirty (e.g. oil, paints, rust, oxides).

Not enough current.

| Cleaning workpieces before welding is inessential method of achieving neat weld beads.
LIMITED PENETRATION| Low current.
High welding rate. Reversed polarity.Electrode inclined in position opposite to its movement.| Make sure operating parameters are regulated and improve preparation of workpieces.
HIGH SPRAYS| Electrode is too inclined.| Make appropriate corrections.
PROFILE DEFECTS| Welding parameters are incorrect. Pass rate is not related to opera-

ting parameters requirements.

| Follow basic and general welding principles.
ARC INSTABILITY| Not enough current.| Check condition of electrode and earth wire connection.
ELECTRODE MELTS OBLIQUELY| Electrode core is not centered. Magnetic blow phenomenon.| Replace electrode.

Connect two earth wires to opposite sides of the workpiece.

TROUBLE SHOOTING

Inverter PCB is defective.

| Check primary connection.

Contact after sales service centre.

NO OUTPUT VOLTAGE| Overheated unit, yellow LED lit

Internal relay has failed. Inverter PCB is defective.

| Wait for thermal cutout to be reset. Check power line. Reset the unit by turning it off and on after 20 seconds.

Contact after sales service centre.

Contact after sales service centre.

WRONG OUTPUT CURRENT| Defective control potentiometer. Low primary power supply voltage.| Contact after sales service centre. Check power line.

DISPOSAL OF WASTE EQUIPMENT BY USERS IN PRIVATE HOUSEHOLDS IN THE EUROPEAN UNION
This symbol on the product or on its packaging indicates that this product must not be disposed of with your other household waste. Instead, it is your responsibility to dispose of your waste equipment by handing it over to a designated collection point for the recycling of waste electrical and electronic equipment. The separate collection and recycling of your waste equipment at the time of disposal will help to conserve natural resources and ensure that it is recycled in a manner that protects human health and the environment. For more information about where you can drop off your waste equipment for recycling, please contact your local city office, your household waste disposal service or the  shop where you purchased the product.

WARRANTY

The legal warranty applies to this welding device. The device was carefully produced according to strict quality guidelines and conscientiously tested before delivery. The warranty period begins on the date of purchase. Please keep the original purchase receipt in a safe place. This document is required as evidence of purchase. If a material or manufacturing defect occurs after the date of purchase of this product, we will, at our option, repair or replace the product free of charge. This service requires that the defective device and the proof of purchase (receipt) are presented within the warranty period and that a brief written description is provided of the nature of the defect and when it occurred.

If the defect is covered by the warranty, you will receive the repaired or a new product back. Repair or replacement of the product does not start a new claim.

Repairs occurring after the expiry of the legally required warranty are subject to a charge.

The performance claims apply to material or manufacturing defects. They do not extend to product parts that are subject to normal usage and can therefore be regarded as wearing parts or to damage to fragile parts.
Claims for performance are forfeited if the product has been damaged, improperly used or maintained. The product is intended for private use only and not for professional use.

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